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The Though Kitchen - Dedicated to Stirring the Pot

Engineering the Perfect Ski: An Interview with Pete Wagner

Posted by leighann | January 8th, 2013 | Filed under Design, Outdoor Sport, Partnerships

Courtesy of Wagner Custom Skis

How do you build the perfect ski? All you need is some sugar maple, Kevlar and the world’s most badass computer algorithm. Oh, and you need Pete Wagner, too. The computer-nerd turned ski-craftsman who started Wagner Custom Skis is single-handedly changing the way an industry makes skis. This week in the Thought Kitchen, we sit down with the man behind the planks to learn more about the number cruncher and his coveted custom boards.

OTG: It’s a bluebird day in Telluride and you’re on the phone talking to me. I’m honored.
Pete: (Laugh) That’s alright, I got out this morning.

OTG: You moved to Telluride in 1998 with a mechanical engineering degree and an impressive career customizing high-end golf clubs. So how does one make the leap from computer nerd to ski-maker?
Pete: Well I bought a pair of telemark skis that I couldn’t demo. But they were the right size, length, width, and they were from a good company, so I bought them anyways. I skied on them for about 70 days, then tried another set and realized I had been crippling myself. At the time, I was working as an engineer developing software for design analysis and manufacturing of golf equipment and I thought, why wasn’t anyone doing this type of fitting technology for skiers? I was spending my energy trying to figure this out in a parallel industry. So that’s what inspired me to create the software for fitting people into the right ski.

OTG: Funny, when I think of making skis, I don’t think of software. And the few boutique ski-makers which do exist in the country mostly rely on precast molds, but you don’t use molds, you use—as you said— software. How’s that possible?
Pete: Our software designs the skis and programs our manufacturing equipment to fabricate all of our parts for the skis. Using high tech machinery, we fabricate all of the components of the skis—the base, bending the steel edges, the wood core, sidewalls, structural layers. Then we use the scrap material from cutting out these different parts—along with our computer-controlled milling equipment—to create the molds for our skis. So every ski gets a unique mold which allows us to go through the same steps each time we build a product, but build a completely unique product every time. It’s a mass customization manufacturing model.

Pete putting the final finish on a pair of Wagner Custom Skis. Image courtesy of Wagner Custom Skis.

OTG: So would you say Wagner Custom Skis are the most customized ski on the market?
Pete: As far as we know. Because every ski we design is uniquely optimized for the individual skier based on length, width, side cut, tail shapes, camber, and rocker. We calibrate the stiffness and flex pattern based on a person’s size and skier preferences. We choose the perfect set of materials, and they get to choose their own graphics.

OTG: You also use Kevlar and Carbon wraps with a traditional wood core. Why do you choose these materials?
Pete: The way we build our skis is the way they built World Cup skis back in the 70’s, and that technology hasn’t changed that much. We take proven materials that work well for ski construction, performance and longevity and we focus on the fit. That way, we can create a design that can help improve someone’s balance, comfort, control, efficiency and power. Ultimately, we create a product that makes skiing easier and more fun for people, and we do that by focusing on the fit rather than trying to reinvent the wheel with materials.

OTG: I think you just answered my next question, but I’ll ask it anyways: How is a Wagner Custom Ski going to change my experience?
Pete: It’s going to help your balance, comfort, control, improve your efficiency, allow you to conserve your leg strength and energy so you can ski longer in the day. It also improves your power, so you can ski with better control and more fluidity. If you look at the best skiers in the world like Bode Miller and Ted Legity, you realize that they aren’t skiing in off-the-shelf skis. They’re sponsored by a company which has a small prototyping shop with a team of dedicated engineers which are making sure that they are on the perfect equipment that will allow them to ski at their absolute highest potential. That’s what Wagner Custom Skis does for recreational skiers. We’re a team of engineers and craftsmen who help people ski their best by making sure they are on their perfect fit equipment.

Courtesy of Wagner Custom Skis

OTG: Well, I’m sold. At Nau, sustainability and performance are two of our core values. And you already touched upon performance as your core value, but how is sustainability reflected in your business?
Pete: We focus on two things: energy and conservation. From an energy perspective, we have a solar thermal system that is on the roof of our building which supplies all of the heat and hot water for our shop. We buy wind energy to run our computers and factory equipment. From a conservation approach, we try and minimize our energy usage by using programmable thermostats and energy efficient lights and work stations to conserving the materials we use and minimizing our waste stream.

OTG: Many people don’t realize that there’s a personal component to sustainability which involves maintaining a sustainable work/life balance, something that’s hard to do as you become more successful. Obviously, you’ve done just that, so how do you strike a balance?
Pete: One thing that we do to help us stay focused on that balance is that we have a Powder Day Clause. So if the snow report for the Telluride Ski Resort shows five inches or more, we work from 1pm to 9pm so that we can get out and take advantage of the best skiing.

OTG: Excuse me, I think I need to go convince our GM to include a Powder Day Clause.

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